FABTECH College of Engineering and Research, Sangola

UNIT 5

UNIT 5

Computer applications in foundry processes, foundry mechanization

Computer applications in foundry processes: Twenty-first century finds us with ever faster and less expensive computing time and extensive use of modeling; we see it on television every day.We can make effective use of this tool in the operations of our metal casting facilities. Modeling is now being used in many other areas of metal casting operations, from simulation of macro segregation and heat treatment to rapid prototyping and facility planning. Benefits: Cost reduction, higher yield, lower rejections, faster development, and Customer satisfaction. Concerns: Initial cost, maintenance cost, technical support, trained manpower. Extensive use of computers is driving the foundry industry in all aspects of development and change, it can not only improve productivity and reduce production costs, but also to promote new technology. Simulation and computer-aided engineering (CAE) applications, can scientifically predict the liquid metal filling process, the solidification process of the temperature field and stress field, and macro-defects and micro-organizations. It can optimize the process to ensure casting quality, reduce trial cycle times, improve competitiveness; can improve the casting at the same time achieve significant economic benefits. Computer applications in the foundry technology development can be described in the following aspects: 1 Casting process with computer-aided design (CAD) technology can be applied for following functional areas: 1. Casting geometry 2. Physical computing (including the casting volume, surface area, weight and thermal modulus calculation) 3. Gating system design calculations (including the choice of casting system type and size of each group element calculation) 4. Feeding system design calculations (including riser, cold iron, and reasonable feeding channel design calculations) 5. Graphics (including casting chart, graph casting process, casting process such as graphics cards Draw and output) As compared to the traditional casting process design, the casting process using computer design features are: 1. The calculation is accurate, rapid, eliminates human error calculation; to mass storage and use of the experience of a number of foundry workers, allows the user to design a more reasonable casting process; with automatic print records and the ability to draw a variety of technical documents.

Manufacturing Processes

Prepared by Prof.S.C.Kulkarni & Prof. Jay Gavade

Page 82

FABTECH College of Engineering and Research, Sangola

UNIT 5

2 Numerical simulation of solidification process technology with the numerical method for solving the physical process of forming the corresponding discrete mathematical equation, which is calculated by the computer displays the results. Achievable goals are: to predict the coagulation time, time out of the box, to determine productivity; predict the formation of shrinkage and shrinkage of the location and size; predict the mold surface and internal temperature distribution, easy cast (especially metal) of design; controlled solidification conditions, to predict the casting stress, micro-and macrosegregation, casting performance, etc. to provide the necessary basis for the calculation and analysis of the data. Numerical simulation of the solidification process can not only show the image of the cavity and the cavity filled with liquid cooling solidification process, can predict possible defects, so the site can be made before the implementation of plans, programs and comprehensive evaluation of various process parameters to optimize technology program to replace or reduce the field trial, which is large and complex shapes or valuable material solidified forming castings, its advantages and economic benefits especially because of the solidification process simulation can reveal the nature of many physical processes, it also contributed to the solidification theory development, research and development in recent years, the microstructure simulation can predict grain size and mechanical properties is expected in the near future for the actual production. 3 Rapid prototyping and manufacturing technology, which is the CAD design data directly into a physical process, it integrates CAD / CAM technology, modern CNC technology, laser technology and new materials technology, no need of drawings & the traditional mold design and processing, greatly improved production efficiency. Has been made using rapid prototyping technology in sand casting, investment casting and solid casting in Rapid appearance of a complex shape or with a laser beam directly to the coated sand mold is made to complete the casting. This high-tech is fundamentally changing the Foundry casting mold making process, showing the efficient, high-quality features. 4 Computer as a production process and the solidification process control methods have been widely used when working conditions are relatively poor, complicated factors, it is necessary to cast the production of in-depth research and extensive. In recent years, there have been a lot of computer analysis of the changes in the production process, using a computer to select the best parameters to regulate the control of the production process, the casting production automation, so as to achieve stable casting quality, increase productivity, reduce the casting cost of the sample. Shape of the current generation of computer-controlled production line has been used to computer-based automatic control system has been used for melting, casting, sand handling, quality inspection processes. The use of computer technology is a prerequisite for producing high-quality castings in foundry.

Manufacturing Processes

Prepared by Prof.S.C.Kulkarni & Prof. Jay Gavade

Page 83

FABTECH College of Engineering and Research, Sangola

UNIT 5

MODERNISATION AND MECHANISATION OF FOUNDRIES

Persons engaged in founding industry have to lead a very hazardous life because of the unhealthy atmosphere inside a foundry. There is thus a vital need for modernisation in this particular field of industry. Measures that lead to increased production, improved quality and reduction in production costs, measures that aim to improve working conditions with an eye to ensuring a safe, healthy and happy life for the worker deserve both modernisation and machanisation.

MODERNISATION
* Modernisation of foundries includes: (1) Changing over to better and newer foundry equipments (2) Employing newer, better, and more economical moulding, melting and casting techniques

(3) Creating conditions which do not make a foundry dirty, dusty and smoke-filled, i.e. improving working condition in foundries, providing adequate illumination, air circulation, dust extraction, etc. * Advantages of modernisation: 1. Improving quality of the casting. 2. Boosting production. 3. Reducing production cost. 4. Increasing safety to the workers. 5. Making working conditions pleasant and less tiring. 6. Building up morale of the workers.

MECHANISATION
Mechanisation implies the utilisation of machinery to accomplish the work previously done by hand. Machinery may be used for preparing sand, moulding and core making, pouring, material handling and many other similar conditions. The extent to which a foundry can be mechanized depends upon the quantity and type of production. For small orders as well as for the production of large-sized castings, mechanisation is both uneconomical and unpractical. On the other hand, a foundry making automobile parts, electric motors, and similar parts where the jobs are of a repetitive nature, mechanisation is economical and practical.

Areas of mechanisation:
Mechainsation has a distinct impact on areas concerned with the preparation and control of sand, moulding and core making, melting and pouring, shake-out operations, material handling, and the control of dust and fume. 1. Sand preparation unit. The sand preparation unit consists of a magnetic separator which removes iron particles from return sand, a auto-riddle which rids foreign materials, a muller which collects the sand for re-use, and aerator which helps to improve the flowability of sand, and a hopper which acts as storage for sand before it is sent for mulling.
Manufacturing Processes Prepared by Prof.S.C.Kulkarni & Prof. Jay Gavade Page 84

FABTECH College of Engineering and Research, Sangola

UNIT 5

2. Moulding and core making unit: This unit uses a large number of different types of moulding and core making machines. The extent to which these equipments can be used depends on the nature of production. 3. Melting, pouring and shake-out unit: It consists of various types of melting furnaces, mechanical charging devices for furnaces, mechanically operated ladles, cranes, lifting tackles, conveyors and vibrating shake-out mechanisms, etc. 4. Material handling unit: This unit includes various types of material handling equipments such as belt conveyors, apron conveyors, flight conveyors, reciprocating and oscillating conveyors, roller conveyors, bucket elevators, mono-rail hoists, different types of cranes and many others for transportation of sand, moulds, cores, molten metal, castings and raw materials required for production. 5. Dust and fume controlling unit: This unit consists of a well-designed dust and fume collector which can clear the polluted air and maintain hygienic working conditions. This includes filter, cyclone, centrifugal dust collector, scrubbers. Fig. shows an automated line for medium moulds with pattern circulating facility, semiautomatic pouring and secondry cooling.

Figure: Automated line for medium size mould production

Advantages of Mechanisation:
1. Increased production from a given foundry floor space and higher productivity. 2. Production of castings that possesses a higher degree of accuracy, closures tolerance, and better surface finish. 3. Enormous saving of time and labour since all operations are carried out mechanically. 4. More hygienic and healthy working conditions, and improved job satisfaction. 5. Minimised casting defects. 6. Reduced production cost and higher profits. 7. increased earnings of the workers.
Manufacturing Processes Prepared by Prof.S.C.Kulkarni & Prof. Jay Gavade Page 85